Electrifying solutions – already in serial production.

The automotive industry is entering a new era, where energy and energy efficiency are taking center stage. Cost-conscious and environmentally aware consumers are calling for vehicles with lower fuel consumption and fewer emissions. Around the globe, exhaust gas standards to reduce CO2 emissions are becoming increasingly stringent, while there is a visible shift towards using electric cars in cities and densely populated areas.

In common with its other products, ElringKlinger is also offering reliability from a single source in the e-mobility sector, from initial idea through design and prototype construction, testing and validation to volume production.

Our expertise in components for energy storage systems

An efficient energy storage system is regarded as the key technology in efforts to develop a viable electric car. The goal is to achieve maximum output and charging capacity as well as absolutely reliable power supply. And, of course, it has to weigh as little as possible.

ElringKlinger is actively shaping the automotive technology of the future. Since early 2011 we have been producing high-performance cell contact systems in cost-efficient series production. We are also pressing ahead with the development of other commercially viable components for lithium-ion batteries and are constantly optimizing our processes as we move forward. Choice of material, design and bonding of the components are being tailored specifically to the requirements of our customers.

Our products

Our high-current-capable contact modules for lithium-ion batteries are tailored precisely to the respective customer requirements and are positioned and welded directly on the group of cells, offering an all-in-one, customized solution.

Other benefits include the optimum compensation of thermal cell expansion and the integration of the necessary sensor technology to monitor current and temperatures. The systems are suitable for use in both hybrid and electric-only vehicles.

Cell contact systems from ElringKlinger are manufactured using a fully automated inline production process and consist of a carrier frame to accommodate busbars and electronic components. The busbars feature a compensating element to reduce the force acting on the cell terminals. Voltage taps monitor the cells and enable active/passive cell balancing. The associated temperature monitor is integrated into the contact system.

Each of our cell contact systems undergoes multiple testing before being shipped to our customers.

Modules as system solution

ElringKlinger also supplies end-to-end solutions, e.g. a 48V module producing 1.7 kWh or a 24V module delivering 750 Wh. The integrated components can be designed according to customer specifications, with the choice of cell depending on the application. Moreover, the modular concept can be used as a stand-alone option or in combination with several modules as a high-voltage storage device.

Busbars

Busbars carry the current between the individual cells of a module. On the one hand, they have to be as flexible and thin as possible to counteract variations between the cells, while on the other, they need a large diameter to be able to transfer the very high currents involved. ElringKlinger’s specific connection solutions offer both the necessary flexibility and the appropriate cross-sections for optimum current carrying capacity.

Weight-reduced battery casing

We also offer casings for energy storage systems with active/passive cooling components and monitoring electronics. Additional components like gaskets, inserts and pressure equalizing elements can be integrated in accordance with customer requirements. What is special about our casings is their lightweight design. Naturally, they also meet electromagnetic compatibility requirements.

Cell casing

By using proven joining processes the necessary material transitions can already be realized in the cell casing itself. Integrated safety devices, like a pressure relief valve that protects the casing if there is a thermal event, are a feature of our cell casings.

Pressure equalizing elements

The housing around an energy storage device represents a large, enclosed air volume. To prevent damage, pressure equalization with the atmosphere is necessary.

ElringKlinger pressure equalizing elements with integrated safety function counteract pressure differences. Thanks to the additional integrated emergency degassing function, the pressure equalizing element opens up a large cross-section in the event of gas emission from a battery cell and therefore allows controlled degassing from the module housing. Thanks to a porous PTFE diaphragm developed in-house, we are able to optimally adjust air flows. In this context, we are able to draw on the PTFE material expertise of our subsidiaryElringKlinger Kunststofftechnik GmbH.

Test and validation laboratory.
Development services by ElringKlinger.

Our purpose-built e-mobility development center accommodates all necessary testing and validation facilities under one roof. Whether you need mechanical, electrical or chemical validation testing, we offer expertise in all processes and can therefore provide our customers with the ideal conditions to explore new directions and reach their goals faster, even for small-batch production. Other automotive suppliers also draw on our expertise and engage us to carry out testing on their behalf. You too can rely on our comprehensive and cost-efficient services.